SERVICING INSTRUCTIONS AND ILLUSTRATED PARTS LIST FOR...
Transcript of SERVICING INSTRUCTIONS AND ILLUSTRATED PARTS LIST FOR...
PAGE 1 © Copyright Hewland Engineering Limited 2001-2009
SERVICING INSTRUCTIONS AND ILLUSTRATED PARTS LIST FOR THE FTR FAMILY OF HEWLAND
GEARBOXES, COVERING FTR, FTRS, FTRL, JFR & LJS UNITS.
HEWLAND ENGINEERING LTD
WALTHAM ROAD, WHITE WALTHAM, MAIDENHEAD, BERKSHIRE,
SL6 3LR, ENGLAND TELEPHONE: +44 (0)1628 827600
Last Updated 10th October 2012
PAGE 2 © Copyright Hewland Engineering Limited 2001-2008
CONTENTS :- Page Technical Specification & Gear Selection 7 General Notes 8 Pinion Setting 9 Differential bearing preload & Crownwheel backlash setting 10 Sequential Fork Setting 13 Changing Gear Ratios 14 Powerflow Differential 15 FTR-212-ADJ Backlash adjustment 16 Gearbox assembly 18
FTR/JFR 6 Speed Illustrated Parts List 20 FTR/JFR 6 Speed (with FTREL Barrel) Illustrated Parts List 29 FTR/JFR 6 Speed conversion to 5 Speed 31 FTR 6 Speed (fitted with FTRE ratios) Illustrated Parts List 32 FTR/JFR 5 Speed Illustrated Parts List 40 FTRS 6 Speed Illustrated Parts List 49 Bearing Carrier Options 50 Differential Options Illustrated Parts List 51 Typical Ramp Orientation 66 Gaitor Assembly 67
PAGE 3 © Copyright Hewland Engineering Limited 2001-2009
CONTENTS :- Page
FTRE and FTRL Lightweight Tripod Assemblies 68 Gearbox Tooling 69 Low Friction Bearing Tooling 71 Installation drawings 72 Pneumatic shift actuator installation 80 FTRL Hubbed 2nd Gears 81 Technical Bulletins 82 General K-Nut Tightening Torques 100 Manual Modification History 101
PAGE 4 © Copyright Hewland Engineering Limited 2001-2008
Page Fig. 1 Pinion Shaft Setting 9 Fig. 2 Backlash Adjustment 11 Fig. 3 Differential Bearing Preload 12 Fig. 4 Sequential Barrel Setting 13 Fig. 5 Powerflow Diff Assembly 15 Fig. 6 FTR-212-ADJ Assembly 16 Fig. 7 FTR-212-ADJ Tooling 17 Fig. 8 Casing & Associated Parts - 6 Speed (not FTRE ratios) 21 Fig. 9 Layshaft Assembly - 6 Speed (not FTRE ratios) 22 Fig. 10 Pinion Shaft Assembly - 6 Speed (not FTRE ratios) 23 Fig. 11 Selector Assembly - 6 Speed (not FTRE ratios) 24 Fig.12 Selector Assembly –6 Speed (FTREL Barrel only) 29 Fig.13 5 Speed Conversion Assembly - 6 Speed Gearbox 31 Fig.14 Casing & Associated Parts - 6 Speed (FTRE ratios) 33 Fig.15 Layshaft Assembly - 6 Speed (FTRE ratios) 34 Fig.16 Pinion Shaft Assembly - 6 Speed (FTRE ratios) 35 Fig.17 Selector Assembly - 6 Speed (FTRE ratios) 36 Fig.18 Casing & Associated Parts - 5 Speed (not FTRE ratios) 41 Fig.19 Layshaft Assembly - 5 Speed (not FTRE ratios) 42 Fig.20 Pinion Shaft Assembly - 5 Speed (not FTRE ratios) 43 Fig.21 Selector Assembly - 5 Speed (not FTRE ratios) 44 Fig.22 FTRS Additional Parts 49
ILLUSTRATIONS:-
PAGE 5 © Copyright Hewland Engineering Limited 2001-2009
ILLUSTRATIONS :- continued
Page Fig.23 Bearing Carrier Options 50 Fig.24 Tripod Differential Assembly 52 Fig.25 FTR-212-FD 53 Fig.26 FTR-212 54 Fig.27 FTRL-212 55 Fig.28 Tripod Adjustable Differential Assembly 56 Fig.29 FTR-212-ADJ 57 Fig.30 Flanged Free Differential 58 Fig.31 LJS-212-F 59 Fig 32 LD-212 60 Fig 33 LD-212-CP 61 Fig.34 Flanged Free Differential Inboard Brake Discs 62 Fig.35 LJS-212-F 63 Fig.36 Flanged LSD Differential Inboard Brake Discs 64 Fig.37 LD-212 65 Fig.38 Ramp Orientation 66 Fig.39 Gaitor Assembly 67 Fig.40 FTRE and FTRL Lightweight Tripod Assemblies 68 Fig.41 Gearbox Tooling 69 Fig.42 Low Friction Bearing Tooling 71 Fig.43 Installation Drawing - FTR 73 Fig.44 Installation Drawing - JFR 74 Fig.45 Installation Drawing - Bearing Carriers 75
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ILLUSTRATIONS :- continued
Page Fig.46a-c Installation Drawing - Flanges 76-79 Fig.47 FTRL Hubbed Gears 81 Fig.48 Technical Bulletin - 01A 84 Fig.49 Technical Bulletin - 02 85 Fig.50 Technical Bulletin - 02 86 Fig.51 Technical Bulletin - 08 92 Fig.52 Technical Bulletin - 013 96 Fig.53 Technical Bulletin - 014 97 Fig.54 Technical Bulletin - 040 99
PAGE 7 © Copyright Hewland Engineering Limited 2001-2009
TECHNICAL SPECIFICATION The FTR gearbox family are transaxle units, designed for mid-engined, rear wheel drive cars. The units are produced with six or five forward gears, reverse, and a differential. The gear selection mechanisms are sequential, with separate mechanically actuated reverse / neutral baulking mechanisms. The gear selection order is Rev - Neutral - 1st 2nd 3rd 4th 5th & 6th (If applicable). The drive is taken from the engine via the clutch shaft, which turns input and pinion gears to drive the final transmission assembly. Gear changing is effected through non-synchronising face dogs. An extensive range of gear ratios provides a wide range of gearing permutations. The gear ratios and differential assembly can easily be changed without removing the gearbox from the vehicle. Heat treated nickel chrome steel is used to manufacture all gears and shafts. The selector forks are also steel. The gearboxes are splash lubricated. In general configuration, the FTR family of gearboxes are high tech racing transaxle units which achieve the maximum effective use of power, in conjunction with extremely stiff integral rear suspension mountings. Weight (Aluminium) FTR(6sp) 88 lbs (40 Kg) Gear ratios from 3.167:1 to .89:1 JFR(6sp) 79 lbs (36 Kg) Final drive ratio 12/34, 9/35 or 9/31 Oil type SAE 80 or 90 Clutch shaft made to customers requirements Oil quantity FTR/JFR(6sp) 4.4 pints (2.5 litres) Pinion shaft nut torque (6sp) = 75 lbs.ft (100 Nm) Maximum engine torque 220 lbs.ft (298 Nm) Pinion shaft nut torque (5sp) = 115 lbs.ft (155Nm) Crownwheel bolt tightening torque = 75 lbs.ft (100 Nm) Engine oil tank capacity (FTR ONLY) 13 pints (7.5 litres) Pinion bearing nut torque = 150 lbs.ft (205 Nm) (FTR FORMULA BMW ONLY) = 130 lbs.ft (176 Nm) (See Page 89 for general K-nut tightening torques)
GEAR SELECTION Up shifting is effected by moving the gear lever in a backward direction. For Downshifting the opposite is necessary. Shifting down into either neutral or reverse is prevented by a baulk plunger. So the plunger operating cable must be pulled before such a shift can be made. Up shifting is as for any other gear, as it does not require the plunger cable to be pulled.
PAGE 8 © Copyright Hewland Engineering Limited 2001-2008
GENERAL NOTES :- a Read these instructions carefully and with reference to the illustrations. b Before dismantling the gearbox, see that a clean tray is available, in which to place the parts. c Thoroughly clean and inspect all parts before reassembly. Discard any worn or damaged components and replace
with new ones. d Use only genuine Hewland parts as replacements. These are manufactured in our workshops to the fine tolerances
necessary and are rigorously inspected. e Always ensure that locknuts, and oil seals are in good condition when reassembling. f All studs and screws must be Loctited or wirelocked in position, unless stated otherwise. g Bearing Replacement :- Bearings can only be removed or renewed if the casings have been warmed in an oven, or with a blowlamp. In the
latter case, keep the blowlamp moving while heating the casing. Note: Do not overheat. Test with a spot of water which will bounce off at the correct temperature. Once a casing is heated, all bearings should be pressed into their respective seatings without delay, thus eliminating
the need to reheat. At the correct temperature, fitting the bearings should present no difficulty. During cooling, or when the casings have cooled, it is advisable to once more lightly press the bearings to ensure
that they are correctly seated. Removal of the existing bearing outer races from the maincase and sideplate can be achieved by locally heating the area of the casings around the bearing outer races with a blowlamp, as above. Light mallet blows around this area will cause the bearing outer to drop away from its location face, it can now be tapped from behind it to remove it. Care must be taken not to damage the shims and spacer located under the race face. h Oil: Fill the gearbox through the plug hole on top of the bearing carrier. The oil will find it's own level within the gearbox. Note: Too much oil will not directly cause any harm, but is undesirable as it may induce power loss and overheating
of internals.
PAGE 9 © Copyright Hewland Engineering Limited 2001-2009
PINION SETTING Special tool No.SK-1709 required for standard FTR configuration Special tool No.SK-2192 required for use with CS-1706-A Sideplate Press the pinion head bearing (57) front inner race onto the pinion shaft (29). Fit the bearing housing (57) and shims (59) into the maincase, and secure with washer and nut. Use socket (SK-247) to tighten the pinion bearing nut to the correct torque (see page 7). Assemble the pinion shaft into the maincase (16), add the pinion head bearing rear inner race, spacer, hubs and bearing inner tracks, pinion tail bearing and pinion shaft nut. Tighten the pinion shaft nut (71) onto the pinion shaft to the correct torque setting using the splined socket and reaction bar. Fit tool SK-1709 into the maincase diff bearing bore, and use feeler gauges to measure the gap between the tool and the pinion front face.This clearance should comply with the dimension indicated on the pinion shaft label (also etched on the front face of the pinion shaft), and can be adjusted by adding or removing shims (59) from behind the pinion head bearing housing (57). Alternatively, the pinion mounting distance can be measured with a height gauge, and set to the dimension on the pinion shaft label. Notes: 1 It is not correct practice to replace a pinion
shaft without measuring the setting distance, even if the old and new shafts have the same calibration.
2. The fork setting should always be checked after replacing or re-shiming the pinion head bearing. Failure to do so may result in poor shift quality, and damaged parts.
Fig.1 (FTR SHOWN)
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Differential Bearing preload To measure the axial bearing preload, fit the differential, bearings, spacers and shims into the maincase then lightly tighten the sideplate in place using the sideplate nuts. Rotate the differential at least 3 turns in order to ensure the bearings are seated correctly, then slacken the sideplate nuts. Evenly spin the sideplate nuts down until they are finger tight (3-4 lbs.ins / 0.34-0.46 Nm) against the sideplate. Check that there is an even gap between the sideplate and maincase. This gap can be measured and the value used as the bearing axial preload.
CW & Pinion Backlash setting Determining the correct fixture settings to achieve the correct backlash at a given bearing pre-load. (See illustrations on following pages) It is assumed that the pinionshaft is fitted and set at the correct position inside the maincase. Build the differential and then press the bearing inners (7) onto the journals and mount the crownwheel onto it. Fit spacer (22) into the maincase bearing bore, followed by a nominal amount of shim (21). A good starting point is probably 0.040” Fit the dummy bearing outer track SK-1715 to the maincase followed by the diff assembly. Fit the second dummy bearing outer track SK-1715 to the setting fixture and position onto the maincase. Secure the fixture to the maincase using all 12 nuts (55) and torque to the value specified on the k-nut tightening torque page. Ensure that the pinionshaft does not run out of backlash whilst tightening the sideplate fixing nuts and add shim if necessary. Please note that it is important to use all nuts torqued to the correct setting, as this affects backlash readings. Fit the nut (SK-1718-A) to the setting fixture (SK-1718-B or SK-2066 for JFR) and wind it by hand into position behind the bearing until a firm ‘stop’ is felt. Use a suitable rod to engage in the hole in the nut if necessary. Unwind the nut by a quarter turn, then whilst rotating the pinionshaft backwards and forwards, wind the nut in by hand until a firm stop is felt. This is important as it ensures the diff is correctly seated in it’s bearings. With a marker pen mark the position of the ‘0’ line on the nut on the setting fixture. This is the 0 bearing preload point. Undo the setting fixture nuts (55) by half a turn or so to release the pressure from the maincase. Wind the nut (SK-1718-A) back into the fixture to the position where the line marked on the fixture lines up with the number on the nut that equates to the pre-load that is required. The nut has a number of lines scribed on it and the number next to it is the pre-load in thousandths of an inch. For example 10 equates to 0.010”. The specified pre-load is 0.013” to 0.015” which is ‘13’ to ‘15’ on the nut.
Alternate CW & Pinion backlash setting and Differential bearing pre-load setting
Special Tools Required: SK-1718-A, SK-1718-B (for JFR use SK-2066), SK-1715 and SK-1913-A
PAGE 11 © Copyright Hewland Engineering Limited 2001-2009
With the nut set at the required bearing pre-load, secure the fixture to the maincase using all 12 nuts (55) torqued to the value specified on the k-nut tightening torque page. Then fit tool SK-1913-A to the spline on the pinionshaft and secure it in position with an M6 cap screw. Measure the backlash at the indicated position on tool SK-1913-A. Rotate the pinionshaft 30° or so and take another reading. Repeat this process until the difference between the minimum and maximum readings is the same as the value for the average backlash variation on the setting sheet. If the minimum reading is outside of what is specified on the spiral bevel setup card, alter the shim (21) inside the maincase. Increasing the shim thickness will reduce the backlash, decreasing it will increase the backlash. (See Fig.1) Run through procedure described above until the backlash is within specification. Calculating correct shimstack. Sideplate shimstack. With the setting fixture secured in position and backlash having been set correctly, measure DIM A using a depth micrometer. This is the distance from the end of the nut to the top face on the setting fixture. Record this dimension. Measure & record DIM B with a height gauge. Record DIM C (this is etched on the face of the nut) Record DIM D (this is etched on the face of the setting fixture) Calculate the total thickness of spacer & shimstack to be fitted to the sideplate:
TOTAL SIDEPLATE SHIM + SPACER THICKNESS = DIM A + DIM B + DIM C - (DIM D + 0.005”)
DIM A “
DIM B “
DIM C “
DIM D “
BACKLASH ADJUSTMENT 12/34 RATIO
0
0.002
0.004
0.006
0.008
0.01
0.012
0.014
0.016
0.0
05
0.0
06
0.0
07
0.0
08
0.0
08
0.0
09
0.0
10
0.0
11
0.0
12
0.0
13
0.0
14
0.0
14
0.0
15
0.0
16
0.0
17
0.0
16
MEASURED BACKLASH
RE
DU
CE
SH
IM B
Y
Fig.2
PAGE 12 © Copyright Hewland Engineering Limited 2001-2008
Maincase shimstack The maincase shimstack to be fitted with the standard bearing outer track (7) rather than the dummy bearing outer track SK-1715 is simply that fitted already minus 0.005”. So simply remove 0.005” from the shimstack used in above section.
Finalising the assembly & checking backlash.
Fit the spacers and shimstack calculated above together with the standard bearing outer tracks to the maincase and sideplate. Allow casings to cool to room temperature and fit diff and sideplate and secure with nuts (55) tightened to the value specified on the k-nut tightening torque page. Check that the backlash is within specification.
Fig.3 (FTR shown)
DIM D WILL BE ETCHED ON FACE
DIM C WILL BE ETCHED ON FACE
SK-1718-B or SK-2066
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PINION SETTING Requires special tool No.SK-1709
Press the pinion head bearing (57) front inner race onto the pinion shaft (29). Fit the bearing housing (57) and shims (59) into the maincase, and secure with washer and nut. Use socket (SK-247) to tighten the pinion bearing nut to the correct torque (see page 7). Assemble the pinion shaft into the maincase (16), add the pinion head bearing rear inner race, spacer, hubs and bearing inner tracks, pinion tail bearing and pinion shaft nut. Tighten the pinion shaft nut (71) onto the pinion shaft to the correct torque setting using the splined socket and reaction bar. Fit tool SK-1709 into the maincase diff bearing bore, and use feeler gauges to measure the gap between the tool and the pinion front face.This clearance should comply with the dimension indicated on the pinion shaft label (also etched on the front face of the pinion shaft), and can be adjusted by adding or removing shims (59) from behind the pinion head bearing housing (57). Alternatively, the pinion mounting distance can be measured with a height gauge, and set to the dimension on the pinion shaft label. Notes: 1 It is not correct practice to replace a pinion shaft without measuring the setting distance, even if the old and
new shafts have the same calibration. 2. The fork setting should always be checked after replacing or re-shiming the pinion head bearing. Failure to do so may result in poor shift quality, and damaged parts.
SEQUENTIAL FORK SETTING The FTR family sequential fork setting procedure is unique amongst Hewland sequential transaxles to date. Previous designs have been fork set by means of a barrel positioning spacer. The FTR family is set by moving the hubs along the pinion shaft by means of a spacer. This fork setting procedure must be carried out each time the pinion head bearing is replaced or re-shimed. a/ Assemble the entire ratchet, barrel, and detent assembly into the maincase. b/ Slide the fork setting spacer, hubs, clutch rings, forks, bearings, inner tracks, and pinion shaft gears into position on the
pinion shaft, and secure with the pinion shaft nut. c/ Engage the selector forks (44) into the barrel (use special tool SK-1716) and slide the selector rail through the forks to
engage the maincase. d/ Rotate the barrel to engage reverse
or neutral. Measure and record the gap between the dogfaces of all gears. Any difference between the dog gap measurements must be averaged out by replacing the barrel spacer (35) with one of the correct thickness.
Note: It is not possible (or necessary) to individually adjust each fork.
Fig.4 (FTR SHOWN) Barrel Spacer (Next to pinion head bearing)
PAGE 14 © Copyright Hewland Engineering Limited 2001-2008
CHANGING GEAR RATIOS
a With a drip tray placed beneath the gearbox, remove the nuts from the rear cover studs, tap the bearing car-rier to break the seal, and drain the oil.
b Remove the bearing carrier.
c Remove the circlip, locking washer and then undo the pinion shaft nut. Withdraw the selector rail about 3/4” until it becomes diengaged from the maincase, then move it to the left to disengage the selector forks from the barrel. Slide the whole gear cluster, together with the selector rail & forks, onto the fixture.
d Remove the selector rail, followed by the gear pairs and other components.
e Replace the gears with the required ratios. Gears are supplied in matched pairs, one for the mainshaft and one for the layshaft. Each gear is marked with two sets of numbers. The first of these indicates the numberof teeth on the layshaft gear, while the second figure signifies the number of teeth on the mainshaft gear which mates with it. Both gears of each pair are marked in an identical manner. It is essential that gears are correctly paired to these numbers. Note: On all first gears, and some second gears, the gear teeth are machined integral with the layshaft. In such cases, therefore, if a first (or second) gear ratio change is required, the layshaft itself must be changed.Whilst changing ratios it is advisable, as a matter of course, to wash and inspect all components which are to be used again before refitting. Check for wear and cracks, particularly to the clutch rings. Also examine the selector forks for heavy or uneven wear.
f Reassembly is the reverse of disassembly. Take care, when refitting the gear cluster into the maincase, to ensure location of the layshaft into it's front bearing. [Some mechanics find assembly easier if the layshaft bearing inner track is pre-fitted in the casing, rather than onto the end of the layshaft.] Special tool SK-1716 is available to help align each selector fork with it’s groove in the barrel. Slide the selector rail forwards to engage in the maincase. Check that all of the selector forks are correctly located in the barrel.
Please note that the order of the gear ratios from the pinion head end are 1st, 2nd, 6th, 5th, 4th and 3rd
PAGE 15 © Copyright Hewland Engineering Limited 2001-2009
3 The second adjustable factor is how tightly the plate stack is compressed on assembly (known as static preload). Included in the plate stack is a preload spacer. The preload torque is measured between the side bevel gears, by holding one side bevel gear stationary and measuring the torque required to turn the other (see tooling page for tools required). When the diff is assembled, the preload torque must be at least 10 lbs.ft, but can be much greater if required. New plates ‘run in’ so a higher preload is advised than with used plates. To assist in
determining the size of the preload spacer, set up shims may be used. They are available in 5 different sizes, .003” .005” .008” .010” .015”
4 The final adjustment is simply to re-order the plate stack so as to
change the number of relatively rotating faces. The diagram shows the stack setup with the maximum 12 working faces. Standard stack may be shuffled to give as few as 2 working faces.
1 The side bevel gears thrust apart to clamp the plates as they transmit the driving power. This is a feature of the gear geometry, and is not adjustable.
2 The ramp angles cut on the side
ring gears have an effect on how much of the transmitted torque is converted into sideways (clamping) force onto the plates. For example, on the drive side ramp, 45 degrees transmits less sideways force than 30 degrees. Likewise on the coast side ramp, an 80 degree angle will transmit little or no clamping force onto the plates, whereas a 45 degree angle will transmit a much greater force. Side ring gears are available with many different drive/coast ramp angle combinations.
Fig.5
POWERFLOW DIFFERENTIAL This powerflow differential unit is designed with versatility as it's major asset. Many factors will contribute to the settings required. A car with good traction and low power, may require a completely different arrangement to that of a car with poor traction and high power. There are 10 friction plates within the unit 4 splined to the diff casing, and 6 splined to the side bevel gears. Slip limiting is dependant on the friction resistance between these plates, and is affected by clamping the plates together.. Four factors contribute to the total friction torque between the plates :-
Clutch Plates
Core Plates
Directio
n o
f C
ar
Planet Gear
6 Working Faces per Side
Right Hand Side Ring Gear
Right Hand Side Bevel Gear 30º
40º
Greater angle transmits less thrust onto plates
Preload Spacer
Direction of force on plates
Fig.5
PAGE 16 © Copyright Hewland Engineering Limited 2001-2008
FTR-212-ADJ BACKLASH ADJUSTMENT
The end float in the tripods determines the amount of backlash in the bevel gears. This end float is changed by machining the top hats (215) as shown below. Set up the differential as shown in the assembly below (Fig 6). Torque the centre bolt (214) to 25Nm and measure the tripod end float. There should be 0.025”-0.030” of end float. If there is more than this, remove material from the spacers so to achieve the require end float. The top hats are deliberately manufactured so that the initial amount of end float is greater than the end float required. When the correct amount of end float is achieved torque and Loctite (No. 648) the centre bolt (214). Item numbers refer to page 53
Fig.6
PAGE 17 © Copyright Hewland Engineering Limited 2001-2009
The FTR-212-ADJ has the advantage of allowing external preload adjust-ment by the turning of a worm screw. To adjust the preload of the differential, insert tool SK-1623 into the worm and turn anti-clockwise to compress the spring to increase the preload. Turn the worm clockwise to decompress the spring and decrease preload. The maximum preload that can be wound onto the differential whilst using 12 friction surfaces is roughly 130lbsft. Fewer friction surfaces will not allow such a large preload figure.
Fig.7
PAGE 18 © Copyright Hewland Engineering Limited 2001-2008
GEARBOX - ASSEMBLY a It is assumed that all bearings, oil seals, studs, and dowels are already fitted into casing. b Slide the rearmost tophat bush into place in the maincase, then slide it rearwards as far as it will go. Push the other
tophat bush into place in the maincase. Press the bearing into the reverse idler gear (39), slide the sleeve into the bearing and position the gear between the tophat bushes. Apply loctite to the retaining bolt and tighten into place.
c Fit the pinion shaft and head bearing assembly to the maincase. d Press the dowel into the maincase. Assemble the detent arm, trunion, washer and spring into the maincase and
secure with screw. e Position the pawl in the slot in the selector rack. Press the pin into place, ensuring that it isn’t left protruding outside
the rack outer diameter. Slide the washers, spring, and sleeve onto the rack, and secure with circlip. Carefully fit the rubber seal onto the rack, taking care that it sits squarely, not twisted, in it’s groove. Oil liberally, and slide the rack into the maincase. Ensure that the rack is free to slide back and forth in the maincase. Any stiction here may cause shift problems in service.
f Put one spacer on the barrel. (Early barrels only). Hold the detent arm against it’s spring using a pair of pliers. Using
a thin rod or stiff wire, push the free end of the pawl upwards in the maincase and hold it there whilst sliding the barrel into place. Slide on the second spacer (Early barrels only), and secure the barrel with the circlip.
g Slide the plunger, spring, and washer into the selector rack, and secure with circlip. Fit the oring to the selector rack
stop, slide the rack stop into the casing and secure with circlip. h Assemble the bell crank, bearings, spacer, and washers to the maincase, and secure with bolt. Note: Select washers
of a thickness so as not to load the casting lugs when tightening the bolt. This could cause casting damage. Ensure that the selector operates smoothly in both directions, and self returns to it’s normal position.
i Add the baulking plunger, o’ring, spring, and cap. Note: when installing the gearbox in the car, the baulk release
cable length should be adjusted so that the baulking plunger is held just clear of the barrel (when a forward gear is selected).
j Fit the wire clip onto the clutch shaft, and push the clutch shaft into the spigot bearing from the gear cluster end. The
PAGE 19 © Copyright Hewland Engineering Limited 2001-2009
wire clip is only fitted to hold the clutch shaft in position when changing ratios. It serves no purpose when the gearbox is fully assembled.
k After adjusting the differential bearing preload and crownwheel backlash. Oil the taper roller bearings then load the
differential assembly in through the sideplate bore, add the sideplate and secure with nuts. l The gear cluster can be built up directly into the gearbox as described below, or built up onto fixture SK-1703. m Slide the spacer and reverse hub onto the pinion shaft. Assemble reverse selector fork onto the reverse pinion gear,
then slide them onto the reverse hub. Allow the reverse fork head to rest against the inside of the maincase. n Slide a bearing inner track and bearing onto the pinion shaft. Holding the layshaft in one hand and 1st pinion gear in
the other, insert them both into position. o Add a hub, clutch ring, and fork, and allow the fork to rest against the maincase. Add the bearing inner track and
bearing, and slide 2nd gear pair into place. p Add another bearing, and slide 6th gear pair into position, (if applicable). Add the hub, clutch ring, bearing inner track
and bearings to the pinion shaft, slide the spacer onto the layshaft, then add 5th gear pair. Repeat for 4th and 3rd gear set.
q Slide the remaining selector forks onto their clutch rings. Insert the selector rail through all the forks, and engage it
into the maincase. Special tool SK-1716 is available to help align the forks with the tracks in the barrel. r Add the thrust washer, bearing inner race, and nut to the pinion shaft. Tighten the nut to the correct torque setting,
then fit the locking ring and secure with circlip, or fit split pin through the nut. s Add the bearing inner track spacer to the layshaft, and fit the bearing inner track into the rear cover. Position the rear
cover and secure with nuts. Check that all gears are selectable, and that the bell crank returns freely to it’s rest position after each shift. Note: The layshaft is located between it’s two bearings and must be preload with spacer. This means that the shaft may be a little stiff to turn when the gearbox is cold.
PAGE 20 © Copyright Hewland Engineering Limited 2001-2008
ILLUSTRATED PARTS LIST FOR 6 SPEED CONFIGURATION OF
FTR, FTRS, FTRL & JFR. (NOT INCLUDING FTRE RATIOS)
PAGE 21 © Copyright Hewland Engineering Limited 2001-2009 Fig.8
CASINGS & ASSOCIATED PARTS– 6 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS)
SEE PAGE 49 FOR JFR
ONLY PART NUMBERS
PAGE 22 © Copyright Hewland Engineering Limited 2001-2008
Fig.9
LAYSHAFT ASSEMBLY—6 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS)
Note orientation of bearing inner track and spacer
The order of the gear ratios from the pinion head end are 1st, 2nd, 6th, 5th, 4th and 3rd
PAGE 23 © Copyright Hewland Engineering Limited 2001-2009
Fig.10
PINION SHAFT ASSEMBLY - 6 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS)
The order of the gear ratios from the pinion head end are 1st, 2nd, 6th, 5th, 4th and 3rd
PAGE 24 © Copyright Hewland Engineering Limited 2001-2008
Fig.11
EARLY
SELECTOR
BARRELS
ONLY
SELECTOR ASSEMBLY—6 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS) FOR ALTERNATIVE LIGHTWEIGHT SELECTOR
SYSTEM SEE PAGE 29
NOTE: For pneumatic shift gearboxes items 23, 24, 78, 83 and 89 should be replaced by item 233
PAGE 25 © Copyright Hewland Engineering Limited 2001-2009
6 SPEED PARTS LIST (NOT SUITABLE FOR USE WITH FTRE RATIOS)
FTR/JFR 6 SPEED ASSEMBLY FTR/JFR 6 SPEED ASSEMBLY
Position QTY Part Number Description Position QTY Part Number Description
1 1 102-260-9 COMPRESSION SPRING 29 1 FINAL-DRIVE FINAL DRIVE ASSY
2 1 105-260-6 NEEDLE ROLLER BEARING 30 2 FTR-225 BEARING INNER TRACK
3 1 BEA-002 ROLLER BEARING 31 2 FTR-226 BEARING INNER TRACK
4 1 BEA-141 BALL BEARING 32
3 (FTR) FTR-227 HUB
5 2 BEA-159 ROLLER BEARING 3 (FTRL) FTRL-227
6 2 BEA-162 BALL BEARING 33
1 (FTR) FTR-228 REVERSE HUB
7 2 BEA-171 TAPER ROLLER BEARING 1 (FTRL) FTRL-228
8 1 CIR-082 CIRCLIP 34 1 LD5-229-4 SPACER
9 1 CIR-083 CIRCLIP 35 1 FTR-229-1 FORK SETTING SPACER
10 1 CIR-084 CIRCLIP 36
1 (FTR) FTR-231 REVERSE SLIDING GEAR
13 2 DGB-239-0 EXTERNAL CIRCLIP 1 (FTRL) FTRL-231
14 1 DOW-024 DOWEL 37 3 FTR-232 CLUTCH RING
15 1 F3A-202-9A DOWEL 38
2 (FTR) FTR-234-1 SPACER-INPUT SHAFT
16 1 (FTR) FTR-201
MAINCASE 2 (FTRL) FTRL-234-1
1 (JFR) JFR-201 39
1 FTR-237 REVERSE IDLER GEAR
17 1 FTR-201-1 SELECTOR RACK STOP 1 FTRL-237
18 1 BEARING-CARRIER BEARING CARRIER 40
2 (FTR), FTR-237-1 REVERSE IDLER SPIGOT
19 1 FTR-202-2 BEARING RETAINING PLATE 1 (JFR)
20 1 (FTR) FTR-205
SIDEPLATE 40 1 (JFR) JFR-237-1 REVERSE IDLER SPIGOT
1 (JFR) JFR-205 41 1 FTR-237-2 SLEEVE
21 2 FTR-205-1 SIDEPLATE SHIM 42 1 FTR-239 CLUTCH SHAFT
22 2 FTR-205-2 SIDEPLATE SPACER 43 1 FTR-246 SELECTOR RAIL
23 1 FTR-210-35 PLUNGER 44 4 FTR-250 SELECTOR FORK
24 1 FTR-210-36 PLUG 45
1 (FTR) FTR-260 SELECTOR BARREL ASSY
25 1 DIFFERENTIAL-ASSY DIFF ASSY 1 (FTRL) FTRL-260
26 2 OUTPUT-FLANGE OUTPUT FLANGE 46 1 FTR-260-2 SPACER TUBE
PARTS DESIGNATED “FTRL” ARE LIGHTENED ALTERNATIVES THAT CAN BE FITTED AS DIRECT REPLACEMENTS FOR STANDARD PARTS.
PAGE 26 © Copyright Hewland Engineering Limited 2001-2008
6 SPEED PARTS LIST Continued (NOT SUITABLE FOR USE WITH FTRE RATIOS)
PARTS DESIGNATED “FTRL” ARE LIGHTENED ALTERNATIVES THAT CAN BE FITTED AS DIRECT REPLACEMENTS FOR STANDARD PARTS.
ITEM 71: WHEN USING A 12:34 CROWNWHEEL AND PINION USE PART: FTR-230-A. WHEN USING A 9:35 OR 9:31 CROWNWHEEL AND PINION USE PART: FTR-230 ITEM 87: WHEN USING A 12:34 CROWN WHEEL AND PINION USE PART: FTR-230-B. WHEN USING A 9:35 OR 9:31 CROWNWHEEL AND PINION USE PART: HP-M-4026
FTR/JFR 6 SPEED ASSEMBLY FTR/JFR 6 SPEED ASSEMBLY
Position QTY Part Number Description Position QTY Part Number Description
47 1 (FTR) FTR-260-3
SELECTOR RACK 68 1 LD-244-10 CIRCLIP
1 (FTRL) FTRL-260-3 69 2 LIP-042 OIL SEAL
48 2 FTR-260-4 SELECTOR RACK WASHER 70 1 LIP-043 OIL SEAL
49 1 FTR-260-5 SLEEVE 71 1 SEE NOTE BELOW LOCK NUT (PIN.TAIL)
50 1 FTR-260-7 BELL CRANK 72 1 ORI-085 QUAD-RING
51 1 FTR-260-8 SPRING TRUNION 73 1 ORI-097 O-RING
52 1 (FTR) FTR-234-ASSY
LAYSHAFT ASSEMBLY 74 1 PCT-260-2 DRUM STOPPER
1 (FTRL) FTRL-234-ASSY 75 1 PCT-260-3 COIL SPRING
53
1 (FTR) FTR-RATIO-HUB HUBBED GEAR PAIR 76 1 PLU-030 PLUG
1 (FTRL) FTRL-RATIO-HUB + FTRL-235-1A
HUBBED GEAR PAIR (SPACER REQUIRED) 77
1 (FTR) SCR-117 SOCKET CAP SCREW
54 4 (FTR) FTR-RATIO-STD STANDARD GEAR PAIR 1 (JFR) SCR-225
4 (FTRL) FTRL-RATIO-STD STANDARD GEAR PAIR 78 2 SCR-121 SOCKET SET SCREW
55 21 NUT-004 KAYNUT 79 1 SPH1077-M3 PAWL
56 1 HC-237-2 NEEDLE ROLLER BEARING 80 1 SPH1078-M3 PLUNGER
57
1
HC8-222-1HB OR LOW FRICTION BEARING BEA-410
PINION HEAD BEARING 81 2 FTR-260-10 BARREL SPACERS
58 1 (FTR)
FGA-222-1A NUT (BMW SPEC FTR ONLY) 82 1 SPR-057 COMPRESSION SPRING
0 (JFR) 82 1 SPR-144
COMPRESSION SPRING (BMW SPEC ONLY)
58 1 NUT-031 NUT (NOT BMW SPEC) 83 1 SPR-058 COMPRESSION SPRING
59 1 HC8-222-2 SHIM 85 8 CROWNWHEEL-BOLT CROWNWHEEL BOLT
60 1 (FTR)
HC8-222-2A WASHER (BMW SPEC FTR ONLY) 86 1 WSH-010 DOWTY WASHER
0 (JFR) 87 1 SEE NOTE BELOW LOCKING RING (PINION)
61 1 HP-M-7039 DRUM WASHER 89 1 ORI-001 O-RING
62 1 HP-M-8008 BALL BEARING 91
1 (FTR) ORI-203 O-RING
63 1 HP-M-9054 SOCKET HEAD CAP SCREW 1 (JFR) ORI-189
64 21 STU-073 STUD 92 22 F3D-236-1 WASHER
65 2 LD-201-5 DOWEL 93 1 NUT-005 KAYNUT
67 6 LD-226-1 NEEDLE CAGE 94 2 HP-N-9006 SOCKET CAP SCREW
PAGE 27 © Copyright Hewland Engineering Limited 2001-2009
6 SPEED PARTS LIST Continued (NOT SUITABLE FOR USE WITH FTRE RATIOS)
PARTS DESIGNATED “FTRL” ARE LIGHTENED ALTERNATIVES THAT CAN BE FITTED AS DIRECT REPLACEMENTS FOR STANDARD PARTS.
FTR/JFR 6 SPEED ASSEMBLY
Position QTY Part Number Description
96 2 HC96-203-18 SOCKET CAP SCREW
97 2 VG-201-1A MAGNET
98 1 HP-M-9008 SOCKET CAP SCREW
100 1 SCR-023 COUNTERSUNK SKT SCREW
101 1 WSH-051 WASHER
102 2 WSH-011 WASHER
103 2 WSH-069 PLAIN WASHER
104 1 TE-201-4 COVER PLATE
105 2 HP-M-9062 SKT BUTTON HEAD SCREW
106 2 HP-N-9004 WIRE CLIP
107 2 GAITOR-KIT (OPT) GAITOR KIT
108 4 LD-202-9 WASHER
109 1 WSH-067 SHIM WASHER
172 1 VG-201-9 SEALING STRIP
181 1 FTR-205-4 BEARING SPACER
182 1 FTR-205-3 BEARING SPACER
183 2 HC9-205-3 BALL BEARING
184 2 CS-1628 BEARING CARRIER
185 2 HC9-205-4 OUTPUT OILSEAL
186 2 CS-1721 OUTPUT FLANGES
187 1 SPA-073 BEARING SPACER
188 1 CS-1631 BEARING SPACER
189 1 CS-1628-B BEARING SPACER
**233 1 PLU-048 BLANKING PLUG
95 2 NUT-007 KAYNUT
PAGE 28 © Copyright Hewland Engineering Limited 2001-2008
6 SPEED VARIABLE PARTS
PAGE 29 © Copyright Hewland Engineering Limited 2001-2009
Fig.12
LIGHTWEIGHT ALTERNATIVE SELECTOR ASSEMBLY—6 SPEED
211
NOTE: For pneumatic shift gearboxes items 23, 24, 78, 83 and 89 should be replaced by item 233
233
PAGE 30 © Copyright Hewland Engineering Limited 2001-2008
FTR 6 SPEED SELECTOR ASSEMBLY USING FTREL BARREL FTR 6 SPEED SELECTOR ASSEMBLY USING FTREL BARREL
Position QTY Part Number Description Position QTY Part Number Description 1 1 102-260-9 COMPRESSION SPRING 72 1 ORI-085 QUAD-RING
2 1 105-260-6 NEEDLE ROLLER BEARING 73 1 ORI-097 O-RING
4 1 BEA-141 BALL BEARING 74 1 PCT-260-2 DRUM STOPPER
6 2 BEA-162 BALL BEARING 75 1 PCT-260-3 COIL SPRING
9 1 CIR-083 CIRCLIP 78 2 SCR-121 SOCKET SET SCREW
13 2 DGB-239-0 EXTERNAL CIRCLIP 79 1 FTRE-260-6 PAWL
14 1 DOW-024 DOWEL 80 1 SPH1078-M3 PLUNGER
15 1 F3A-202-9A DOWEL 82 1 SPR-057 COMPRESSION SPRING
17 1 FTR-201-1 SELECTOR RACK STOP 83 1 SPR-058 COMPRESSION SPRING
19 1 FTR-202-2 BEARING RETAINING PLATE 89 1 ORI-001 O-RING
23 1 FTR-210-35 PLUNGER 93 1 NUT-005 KAYNUT
24 1 FTR-210-36 PLUG 94 2 HP-N-9006 SOCKET CAP SCREW
43 1 FTRE-246 SELECTOR RAIL 98 1 HP-M-9008 SOCKET CAP SCREW
44 3 FTRE-250 SELECTOR FORK 108 4 LD-202-9 WASHER
45 1 FTREL-260 SELECTOR BARREL ASSY 109 1 WSH-067 SHIM WASHER
46 1 FTR-260-2 SPACER TUBE 190 1 FTRE-260-9 PIVOT PIECE
47 1 FTRE-260-3 SELECTOR RACK 191 2 FTRE-260-9A PIVOT PINS
48 2 FTR-260-4 SELECTOR RACK WASHER 192 4 CIR-054 CIRCLIPS
49 1 FTRE-260-5 SLEEVE 193 1 FTRE-260-3A RACK PLUG
50 1 FTRE-260-7 BELL CRANK 207 1 FTRE-201-1 PILLAR SPACER
51 1 FTR-260-8 SPRING TRUNION 210 1 FTRE-249 REVERSE FORK
61 1 HP-M-7039 DRUM WASHER 211 1 FTRE-231 REVERSE SLIDING GEAR
63 1 SCR-152 SOCKET HEAD CAP SCREW 233** 1 PLU-048 BLANKING PLUG
LIGHTWEIGHT ALTERNATIVE SELECTOR ASSEMBLY—6 SPEED (NOT FOR USE WITH FTRE RATIO’S)
DARKER COLOURS REPRESENT NEW PARTS, GREY PARTS ARE THE SAME AS THOSE WITH THE STANDARD SELECTOR SYSTEM
** = FOR USE IN PNEUMATIC SHIFT GEARBOXES
PAGE 31 © Copyright Hewland Engineering Limited 2001-2009
Fig.13
5 SPEED CONVERSION OF 6 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS)
PAGE 32 © Copyright Hewland Engineering Limited 2001-2008
FTRE RATIO CONFIGURATION NOW OBSOLETE (USED IN 2008 ONLY)
ILLUSTRATED PARTS LIST FOR 6 SPEED CONFIGURATION OF
FTR FITTED WITH FTRE RATIOS.
PAGE 33 © Copyright Hewland Engineering Limited 2001-2009
CASINGS & ASSOCIATED PARTS 6 SPEED (FTRE RATIOS ONLY)
Fig.14
FTRE RATIO CONFIGURATION NOW OBSOLETE (USED IN 2008 ONLY)
PAGE 34 © Copyright Hewland Engineering Limited 2001-2008
LAYSHAFT ASSEMBLY—6 SPEED (FTRE RATIOS ONLY)
Fig.15
FTRE RATIO CONFIGURATION NOW OBSOLETE (USED IN 2008 ONLY)
The order of the gear ratios from the pinion head end are 1st, 2nd, 6th, 5th, 4th and 3rd
PAGE 35 © Copyright Hewland Engineering Limited 2001-2009
PINION SHAFT ASSEMBLY - 6 SPEED (FTRE RATIOS ONLY)
Fig.16
194
194
FTRE RATIO CONFIGURATION NOW OBSOLETE (USED IN 2008 ONLY)
The order of the gear ratios from the pinion head end are 1st, 2nd, 6th, 5th, 4th and 3rd
PAGE 36 © Copyright Hewland Engineering Limited 2001-2008
SELECTOR ASSEMBLY—6 SPEED (FTRE RATIOS ONLY)
Fig.17
FTRE RATIO CONFIGURATION NOW OBSOLETE (USED IN 2008 ONLY)
PAGE 37 © Copyright Hewland Engineering Limited 2001-2009
FTR 6 SPEED ASSEMBLY USING FTRE RATIOS FTR 6 SPEED ASSEMBLY USING FTRE RATIOS
Position QTY Part Number Description Position QTY Part Number Description
1 1 102-260-9 COMPRESSION SPRING 33 1 FTRE-228 REVERSE HUB
2 1 105-260-6 NEEDLE ROLLER BEARING 34 1 FTRE-224 SPACER
3 1 BEA-002 ROLLER BEARING 35 1 FTR-229-1 FORK SETTING SPACER
4 1 BEA-141 BALL BEARING 36 1 FTRE-231 REVERSE SLIDING GEAR
5 2 BEA-159 ROLLER BEARING 37 3 FTR-232 CLUTCH RING
6 2 BEA-162 BALL BEARING 38 2 FTRE-234-1 SPACER-INPUT SHAFT
7 2 BEA-171 TAPER ROLLER BEARING 42 1 FTR-239 CLUTCH SHAFT
9 1 CIR-083 CIRCLIP 43 1 FTRE-246 SELECTOR RAIL
13 2 DGB-239-0 EXTERNAL CIRCLIP 44 3 FTRE-250 SELECTOR FORK
14 1 DOW-024 DOWEL 45 1 FTRE-260 SELECTOR BARREL ASSY
15 1 F3A-202-9A DOWEL 46 1 FTR-260-2 SPACER TUBE
16 1 FTR-201 MAINCASE 47 1 FTRE-260-3 SELECTOR RACK
17 1 FTR-201-1 SELECTOR RACK STOP 48 2 FTR-260-4 SELECTOR RACK WASHER
18 1 BEARING-CARRIER BEARING CARRIER 49 1 FTRE-260-5 SLEEVE
19 1 FTR-202-2 BEARING RETAINING PLATE 50 1 FTRE-260-7 BELL CRANK
20 1 FTR-205 SIDEPLATE 51 1 FTR-260-8 SPRING TRUNION
21 2 FTR-205-1 SIDEPLATE SHIM 52 1 FTRE-234-ASSY LAYSHAFT ASSEMBLY
22 2 FTR-205-2 SIDEPLATE SPACER 53 1 FTRE-RATIO-2ND FTR 2ND GEAR PAIR
23 1 FTR-210-35 PLUNGER 54 4 FTRE-RATIO-STD FTRE STANDARD GEAR PAIR
24 1 FTR-210-36 PLUG 55 21 NUT-004 KAYNUT
25 1 DIFFERENTIAL-ASSY DIFF ASSY 57 1 HC8-222-1HB OR LOW FRICTION
PINION HEAD BEARING
26 2 OUTPUT-FLANGE OUTPUT FLANGE 1 FGA-222-1A NUT (BMW SPEC FTR ONLY)
29 1 FINAL-DRIVE FINAL DRIVE ASSY 1 NUT-031 NUT (NOT BMW SPEC)
30 1 FTRE-225 BEARING INNER TRACK 59 1 HC8-222-2 SHIM
31 2 FTRE-226 BEARING INNER TRACK 60 1 HC8-222-2A WASHER (BMW FTR ONLY)
32 3 FTRE-227 HUB 61 1 HP-M-7039 DRUM WASHER
58
6 SPEED PARTS LIST (FTRE RATIOS ONLY)
FTRE RATIO CONFIGURATION NOW OBSOLETE (USED IN 2008 ONLY)
PAGE 38 © Copyright Hewland Engineering Limited 2001-2008
FTR 6 SPEED ASSEMBLY USING FTRE RATIOS FTR 6 SPEED ASSEMBLY USING FTRE RATIOS
Position QTY Part Number Description Position QTY Part Number Description
62 1 HP-M-8008 BALL BEARING 96 2 HC96-203-18 SOCKET CAP SCREW
1 SCR-152 97 2 VG-201-1A MAGNET
64 21 STU-073 STUD 98 1 HP-M-9008 SOCKET CAP SCREW
65 2 LD-201-5 DOWEL 100 1 SCR-023 COUNTERSUNK SKT SCREW
67 6 LD-226-1 NEEDLE CAGE 101 1 WSH-051 WASHER
68 1 LD-244-10 CIRCLIP 102 2 WSH-011 WASHER
69 2 LIP-042 103 2 WSH-069 PLAIN WASHER
1 LIP-043 104 1 TE-201-4 COVER PLATE
71 1 LOCK NUT (PIN.TAIL) LOCK NUT (PIN.TAIL) 105 2 HP-M-9062 SKT BUTTON HEAD SCREW
72 1 ORI-085 QUAD-RING 2 HP-N-9004
73 1 ORI-097 O-RING 107 2 GAITOR-KIT (OPT) GAITOR KIT
74 1 PCT-260-2 DRUM STOPPER 108 4 LD-202-9 WASHER
75 1 PCT-260-3 COIL SPRING 109 1 WSH-067 SHIM WASHER
76 1 PLU-030 PLUG 172 1 VG-201-9 SEALING STRIP
1 181 1 FTR-205-4 BEARING SPACER
80 1 SPH1078-M3 PLUNGER 182 1 FTR-205-3 BEARING SPACER
82 1 SPR-057 COMPRESSION SPRING 183 2 HC9-205-3 BALL BEARING
83 1 SPR-058 COMPRESSION SPRING 184 2 CS-1628 BEARING CARRIER
8 185 2 HC9-205-4 OUTPUT OILSEAL
86 1 WSH-010 DOWTY WASHER 186 2 CS-1671 OUTPUT FLANGES
87 1 LOCKING RING LOCKING RING (PINION) 1 SPA-073
89 1 ORI-001 O-RING 188 1 CS-1631 BEARING SPACER
91 1 ORI-203 O-RING 189 1 CS-1628-B BEARING SPACER
93 1 NUT-005 KAYNUT 190 1 FTRE-260-9 PIVOT PIECE
94 2 HP-N-9006 SOCKET CAP SCREW 191 2 FTRE-260-9A PIVOT PINS
95 2 NUT-007 KAYNUT 192 4 CIR-054 CIRCLIPS
OIL SEAL
63 SOCKET HEAD CAP SCREW
70 OIL SEAL
FTRE-260-6 PAWL
85 CROWNWHEEL-BOLT CROWNWHEEL BOLT
79
187 BEARING SPACER
106 WIRE CLIP
6 SPEED PARTS LIST Continued (FTRE RATIOS ONLY)
FTRE RATIO CONFIGURATION NOW OBSOLETE (USED IN 2008 ONLY)
PAGE 39 © Copyright Hewland Engineering Limited 2001-2009
FTR 6 SPEED ASSEMBLY USING FTRE RATIOS
Position QTY Part Number Description 193 1 FTRE-260-3A RACK PLUG
194 5 BEA-395 NEEDLE ROLLERS
195 1 HP-M-9042 DOWTY WASHER
196 1 SPA-077 SENSOR SPACER
200 1 FTRE-237-1 REVERSE POST
201 1 WSH-089 WASHER
202 1 BEA-401 NEEDLE ROLLER
203 1 FTRE-237 REVERSE IDLER GEAR
204 1 SCR-129 SCREW
205 1 FTRE-237-2 BUSH
206 1 FTRE-237-4 INSERT
207 1 FTRE-201-1 PILLAR SPACER
208 1 FTRE-234-2 SPACER
209 1 FTRE-234-3 SPACER
210 1 FTRE-249 REVERSE FORK
211 1 FTR-212-ADJ ADJUSTABLE DIFF ASSEMBLY
212 1 FTR-218-15 OUTPUT FLANGE
213 1 FTR-218-16 OUTPUT FLANGE
214 1 SCR-119 BI-HEX BOLT
215 2 FTR-213-9 TOP HAT BUSHES
216 2 FTR-213-11 TRIPOD INSERTS
217 1 NUT-004 KAYNUT
6 SPEED PARTS LIST Continued (FTRE RATIOS ONLY)
FTRE RATIO CONFIGURATION NOW OBSOLETE (USED IN 2008 ONLY)
PAGE 40 © Copyright Hewland Engineering Limited 2001-2008
ILLUSTRATED PARTS LIST FOR 5 SPEED CONFIGURATIONS OF
FTR, FTRS, JFR & LJS. (NOT INCLUDING FTRE RATIOS)
PAGE 41 © Copyright Hewland Engineering Limited 2001-2009
CASINGS & ASSOCIATED PARTS– 5 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS)
Fig.18
THESE PARTS ARE FTR/JFR MAINCASE SPECIFIC
SEE PAGE 49 FOR JFR
ONLY PART NUMBERS
PAGE 42 © Copyright Hewland Engineering Limited 2001-2008
Fig.19
LAYSHAFT ASSEMBLY—5 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS)
The order of the gear ratios from the pinion head end are 1st, 2nd, 5th, 4th and 3rd
PAGE 43 © Copyright Hewland Engineering Limited 2001-2009
Fig.20
PINION SHAFT ASSEMBLY– 5 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS)
The order of the gear ratios from the pinion head end are 1st, 2nd, 6th, 5th, 4th and 3rd
PAGE 44 © Copyright Hewland Engineering Limited 2001-2008
Fig.21
SELECTOR ASSEMBLY- 5 SPEED (NOT SUITABLE FOR USE WITH FTRE RATIOS)
NOTE: For pneumatic shift gearboxes items 23, 24, 78, 83 and 89 should be replaced by item 233
233
PAGE 45 © Copyright Hewland Engineering Limited 2001-2009
5 SPEED PARTS LIST (NOT SUITABLE FOR USE WITH FTRE RATIOS)
FTR/JFR 5 SPEED ASSEMBLY FTR/JFR 5 SPEED ASSEMBLY
Position QTY Part Number Description Position QTY Part Number Description
1 1 102-260-9 COMPRESSION SPRING 28 2 FTR-218-3 BEARING RING
2 1 105-260-6 NEEDLE ROLLER BEARING 29 1 FINAL-DRIVE FINAL DRIVE ASSY
3 1 BEA-002 ROLLER BEARING 30 2 FTR-225 BEARING INNER TRACK
4 1 BEA-141 BALL BEARING 31 2 FTR-226 BEARING INNER TRACK
5 2 BEA-159 ROLLER BEARING 32
3 FTR-227 HUB
6 2 BEA-162 BALL BEARING 3 FTRL-227
7 2 BEA-171 TAPER ROLLER BEARING 33 1 FTR-228 REVERSE HUB
8 1 CIR-082 CIRCLIP 34 1 LD5-229-4 SPACER
9 1 CIR-083 CIRCLIP 35 1 FTR-229-1 FORK SETTING SPACER
10 1 CIR-084 CIRCLIP 36 1 FTR-231 REVERSE SLIDING GEAR
13 2 DGB-239-0 EXTERNAL CIRCLIP 37 3 FTR-232 CLUTCH RING
14 1 DOW-024 DOWEL 38
2 FTR-234-1 SPACER-INPUT SHAFT
15 1 F3A-202-9A DOWEL 2 FTRL-234-1
16 1 FTR-201 (FTR)
MAINCASE 39 1 FTR-237
REVERSE IDLER GEAR 1 JFR-201 (JFR) 1 FTRL-237
17 1 FTR-201-1 SELECTOR RACK STOP 40
1 (FTR), JFR-237-1 REVERSE IDLER SPIGOT 18 1 BEARING-CARRIER BEARING CARRIER 1 (JFR)
19 1 FTR-202-2 BEARING RETAINING PLATE 40 1 (JFR) FTR-237-1 REVERSE IDLER SPIGOT
20 1 FTR-205 (FTR)
SIDEPLATE 40 1 (FTR) FTR-237-3 REVERSE IDLER SPIGOT
1 JFR-205 (JFR) 41 1 FTR-237-2 SLEEVE
21 2 FTR-205-1 SIDEPLATE SHIM 42 1 FTR-239 CLUTCH SHAFT
22 2 FTR-205-2 SIDEPLATE SPACER 43 1 FTR-246 SELECTOR RAIL
23 1 FTR-210-35 PLUNGER 44 4 FTR-250 SELECTOR FORK
24 1 FTR-210-36 PLUG 45 1 FTR-260 SELECTOR BARREL ASSY
25 1 DIFFERENTIAL-ASSY DIFF ASSY 46
1 FTR-260-2
26 2 OUTPUT-FLANGE OUTPUT FLANGE SPACER TUBE
PARTS DESIGNATED “FTRL” ARE LIGHTENED ALTERNATIVES THAT CAN BE FITTED AS DIRECT REPLACEMENTS FOR STANDARD PARTS.
PAGE 46 © Copyright Hewland Engineering Limited 2001-2008
5 SPEED PARTS LIST Continued (NOT SUITABLE FOR USE WITH FTRE RATIOS)
FTR/JFR 5 SPEED ASSEMBLY FTR/JFR 5 SPEED ASSEMBLY
Posi-tion QTY Part Number Description Position QTY Part Number Description
47 1 FTR-260-3
SELECTOR RACK 69 2 LIP-042 OIL SEAL
1 FTRL-260-3 70 1 LIP-043 OIL SEAL
48 2 FTR-260-4 SELECTOR RACK WASHER 71 1 FT-230 LOCK NUT (PIN.TAIL)
49 1 FTR-260-5 SLEEVE 72 1 ORI-085 QUAD-RING
50 1 FTR-260-7 BELL CRANK 73 1 ORI-097 O-RING
51 1 FTR-260-8 SPRING TRUNION 74 1 PCT-260-2 DRUM STOPPER
52 LJS-RATIO-INT LAYSHAFT ASSEMBLY 75 1 PCT-260-3 COIL SPRING
76 1 PLU-030 PLUG
53 1 JFR-RATIO-HUB HUBBED GEAR PAIR 77
1 (FTR) SCR-117 SOCKET CAP SCREW
54 4 FTR-RATIO-STD FTR STANDARD GEAR PAIR 1 (JFR) SCR-225
55 21 NUT-004 KAYNUT 78 2 SCR-121 SOCKET SET SCREW
56 1 HC-237-2 NEEDLE ROLLER BEARING 79 1 SPH1077-M3 PAWL
57 1 HC8-222-1HB OR LOW FRICTION
PINION HEAD BEARING 80 1 SPH1078-M3 PLUNGER
58 1 (FTR)
FGA-222-1A NUT (BMW SPEC FTR ONLY) 81 2 FTR-260-10 BARREL SPACERS
0 (JFR) 82 1 SPR-057 COMPRESSION SPRING
58 1 NUT-031 NUT (NOT BMW SPEC) 83 1 SPR-058 COMPRESSION SPRING
59 1 HC8-222-2 SHIM 85 8 CROWNWHEEL-BOLT CROWNWHEEL BOLT
60 1 (FTR) HC8-222-2A
WASHER (BMW FTR ONLY) 86 1 WSH-010 DOWTY WASHER
0 (JFR) HC8-222-2A 87 1 FT-230-1 SPLIT PIN
61 1 HP-M-7039 DRUM WASHER 89 1 ORI-001 O-RING
62 1 HP-M-8008 BALL BEARING 91
1 (FTR) ORI-203 O-RING
63 1 HP-M-9054 SOCKET HEAD CAP SCREW 1 (JFR) ORI-189
64 21 STU-073 STUD 92 22 F3D-236-1 WASHER
65 2 LD-201-5 DOWEL 93 1 NUT-005 KAYNUT
67 6 LD-226-1 NEEDLE CAGE 94 2 HP-N-9006 SOCKET CAP SCREW
68 1 LD-244-10 CIRCLIP 95 2 NUT-007 KAYNUT
1
PARTS DESIGNATED “FTRL” ARE LIGHTENED ALTERNATIVES THAT CAN BE FITTED AS DIRECT REPLACEMENTS FOR STANDARD PARTS.
PAGE 47 © Copyright Hewland Engineering Limited 2001-2009
5 SPEED PARTS LIST Continued (NOT SUITABLE FOR USE WITH FTRE RATIOS)
PARTS DESIGNATED “FTRL” ARE LIGHTENED ALTERNATIVES THAT CAN BE FITTED AS DIRECT REPLACEMENTS FOR STANDARD PARTS.
FTR/JFR 5 SPEED ASSEMBLY
Position QTY Part Number Description 96 2 HC96-203-18 SOCKET CAP SCREW
97 2 VG-201-1A MAGNET
98 1 HP-M-9008 SOCKET CAP SCREW
100 1 SCR-023 COUNTERSUNK SKT SCREW
101 1 WSH-051 WASHER
102 2 WSH-011 WASHER
103 2 WSH-069 PLAIN WASHER
104 1 TE-201-4 COVER PLATE
105 2 HP-M-9062 SKT BUTTON HEAD SCREW
106 2 HP-N-9004 WIRE CLIP
107 2 GAITOR-KIT (OPT) GAITOR KIT
108 4 LD-202-9 WASHER
109 1 WSH-067 SHIM WASHER
160 1 HYD-026 BLANKING PLUG
161 1 400-868-4490-41 DOWTY WASHER
162 1 LD-205-2A BEARING SPACER
163 2 LD-205-3 BALL BEARING
164 2 LJS-201-1 BEARING CARRIER
165 1 LJS-221-1 BEARING INNER TRACK
166 2 ORI-006 O-RING
168 1 SCR-097 SOCKET SET SCREW
169 2 FT-219-1A CIRCLIP
170 1 FTR-225 BEARING INNER TRACK
172 1 VG-201-9 SEALING STRIP
233** 1 PLU-048 BLANKING PLUG
PAGE 48 © Copyright Hewland Engineering Limited 2001-2008
5 SPEED VARIABLE PARTS
PAGE 49 © Copyright Hewland Engineering Limited 2001-2009
FTRS SPEC ONLY
Position QTY Part Number
16 1 FTRS-201 MAINCASE
20 1 FTRS-205 SIDEPLATE
64 11 STU-036 STUD
SEE BELOW 2 SCR-218 SOCKET HEAD SCREW
SEE BELOW 2 ORI-037 O-RING
JFR ONLY
Position QTY Part Number 150 1 HP-M-9037 BANJO JOINTS
151 1 HP-M-9039 BANJO BOLT
152 2 HP-M-9038 SEALING WASHER
153 1 SCR-048 SOCKET HEAD SCREW
154 1 ORI-080 O-RING
155 1 PLU-059 PLUG
BMW SPEC ONLY
Position QTY Part Number 50 1 663-6-120 RHS ONLY
52 1 7772376 LAYSHAFT RATIO 12:38
53 1 7772377 GEAR RATIO HUB 15:32
53 1 7772378 GEAR RATIO HUB 15:33
54 1 7772379 GEAR RATIO 15:25
54 1 7772380 GEAR RATIO 16:23
54 1 7772381 GEAR RATIO 17:26
54 1 7772382 GEAR RATIO 17:30
54 1 7772383 GEAR RATIO 18:19
54 1 7772384 GEAR RATIO 18:27
54 1 7772385 GEAR RATIO 18:24
54 1 7772386 GEAR RATIO 18:25
54 1 7772387 GEAR RATIO 19:21
54 1 7772388 GEAR RATIO 21:24
54 1 7772389 GEAR RATIO 21:25
54 1 7772390 GEAR RATIO 21:26
54 1 7772393 GEAR RATIO 19:23
FTRS Edition additional
parts layout
Fig.22
PAGE 50 © Copyright Hewland Engineering Limited 2001-2008
Fig.23
BEARING CARRIER OPTIONS
PAGE 51 © Copyright Hewland Engineering Limited 2001-2009
ILLUSTRATED PARTS LIST FOR DIFFERENTIAL CONFIGURATIONS
PAGE 52 © Copyright Hewland Engineering Limited 2001-2008
Fig.24
TRIPOD DIFFERENTIAL ASSEMBLY
7
PAGE 53 © Copyright Hewland Engineering Limited 2001-2009
OUTPUT TRIPODS
AVAILABLE
FTR-218-FD
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 BEA-171 TAPER ROLLER BEARING BEA-171 TAPER ROLLER BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 FTR-205-1 SIDEPLATE SHIM FTR-205-1 SIDEPLATE SHIM
22 FTR-205-2 SIDEPLATE SPACER FTR-205-2 SIDEPLATE SPACER
69 LIP-042 LIPSEAL LIP-042 LIPSEAL
91 ORI-203 O-RING ORI-189 O-RING
There is a Gaitor kit option
with these tripods, see Gai-
tor Assembly page
FTR-212-FD FREE DIFFERENTIAL ASSEMBLY AS USED IN STAR MAZDA SPECIFICATION
Fig.25
# REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
part numbers BEA-171 CAN BE REPLACED WITH
LOW FRICTION BEARING BEA-408
PAGE 54 © Copyright Hewland Engineering Limited 2001-2008
OUTPUT TRIPODS
AVAILABLE
FTR-218-8
FTR-218-1AS
FTR-218-7AS
FTR-218-2
FTRL-218-3
FTRL-218-4
Fig.26
There is a
Gaitor kit op-
tion with
these tripods,
see Gaitor As-
sembly page
FTR-212 LIMITED SLIP DIFFERENTIAL
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 BEA-171 TAPER ROLLER BEARING BEA-171 TAPER ROLLER BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 FTR-205-1 SIDEPLATE SHIM FTR-205-1 SIDEPLATE SHIM
22 FTR-205-2 SIDEPLATE SPACER FTR-205-2 SIDEPLATE SPACER
69 LIP-042 LIPSEAL LIP-042 LIPSEAL
91 ORI-203 O-RING ORI-189 O-RING
# REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
part numbers
BEA-171 CAN BE REPLACED WITH
LOW FRICTION BEARING BEA-408
PAGE 55 © Copyright Hewland Engineering Limited 2001-2009
OUTPUT TRIPODS
AVAILABLE
FTRL-218-1C
FTRL-218-2C
FTRL-218-3
FTRL-218-4
Fig.27
There is a Gaitor
kit option with
these tripods, see
Gaitor Assembly
page
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 BEA-171 TAPER ROLLER BEARING BEA-171 TAPER ROLLER BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 FTR-205-1 SIDEPLATE SHIM FTR-205-1 SIDEPLATE SHIM
22 FTR-205-2 SIDEPLATE SPACER FTR-205-2 SIDEPLATE SPACER
69 LIP-042 LIPSEAL LIP-042 LIPSEAL
91 ORI-203 O-RING ORI-189 O-RING
FTRL-212 DIFFERENTIAL ASSEMBLY AS USED IN DALLARA F3 2005 SPECIFICATION
# REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
part numbers
BEA-171 CAN BE REPLACED WITH
LOW FRICTION BEARING BEA-408
PAGE 56 © Copyright Hewland Engineering Limited 2001-2008
FTR-212-ADJ PRELOAD ADJUSTABLE DIFFERENTIAL ASSEMBLY WITH TRIPODS
Fig.28
PAGE 57 © Copyright Hewland Engineering Limited 2001-2009
Fig.29
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 BEA-171 TAPER ROLLER BEARING BEA-171 TAPER ROLLER BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 FTR-205-1 SIDEPLATE SHIM FTR-205-1 SIDEPLATE SHIM
22 FTR-205-2 SIDEPLATE SPACER FTR-205-2 SIDEPLATE SPACER
69 LIP-042 LIPSEAL LIP-042 LIPSEAL
91 ORI-203 O-RING ORI-189 O-RING
214 SCR-119 BI-HEX BOLT SCR-119 BI-HEX BOLT
215 FTR-213-9 TOP HAT BUSHES FTR-213-9 TOP HAT BUSHES
216 FTR-213-11 TRIPOD INSERTS FTR-213-11 TRIPOD INSERTS
217 NUT-004 KAYNUT NUT-004 KAYNUT
FTR-212-ADJ ADJUSTABLE DIFFERENTIAL ASSEMBLY
There is a Gaitor
kit option with
these tripods, see
Gaitor Assembly
page
OUTPUT TRIPODS
AVAILABLE
FTR-218-15
FTR-218-16
FTRE-218-LAS
FTRE-218-RAS # REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
part numbers
BEA-171 CAN BE REPLACED WITH
LOW FRICTION BEARING BEA-408
PAGE 58 © Copyright Hewland Engineering Limited 2001-2008
Fig.30
FLANGED ALTERNATIVE DIFFERENTIAL ASSEMBLY
190
PAGE 59 © Copyright Hewland Engineering Limited 2001-2009
Fig.31
LJS-212-F FREE DIFFERENTIAL
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 HC9-205-1 BEARING HC9-205-1 BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 HC9-206-1 SHIM HC9-206-1 SHIM
22 LD-205-2 SPACER LD-205-2 SPACER
69 LD-205-4 OILSEAL LD-205-4 OILSEAL
91 ORI-203 O-RING ORI-189 O-RING
162 LD-205-2A LH BEARING SPACER LD-205-2A LH BEARING SPACER
163 LD-205-3 BALL BEARING LD-205-3 BALL BEARING
164 LJS-201-1 BEARING CARRIER LJS-201-1 BEARING CARRIER
166 ORI-006 O-RING ORI-006 O-RING
169 FT-219-1A CIRCLIP FT-219-1A CIRCLIP
190 LJS-201-1 BEARING CARRIER LJS-201-1 BEARING CARRIER
OUTPUT FLANGES AVAILABLE
LJS-218
LD-218-LH x2
# REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
part numbers
PAGE 60 © Copyright Hewland Engineering Limited 2001-2008
LD-212 LIMITED SLIP DIFFERENTIAL
Fig.32
# REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
part numbers
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 HC9-205-1 BEARING HC9-205-1 BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 HC9-206-1 SHIM HC9-206-1 SHIM
22 LD-205-2 LH BEARING SPACER LD-205-2 LH BEARING SPACER
69 LD-205-4 OILSEAL LD-205-4 OILSEAL
91 ORI-203 O-RING ORI-189 O-RING
162 CS-1706-C SPACER CS-1706-C SPACER
163 LD-205-3 BALL BEARING LD-205-3 BALL BEARING
164 CS-1706-B BEARING CARRIER CS-1706-B BEARING CARRIER
166 ORI-006 O-RING ORI-006 O-RING
169 FT-219-1A CIRCLIP FT-219-1A CIRCLIP
190 CS-1706-A BEARING CARRIER CS-1706-A BEARING CARRIER FOR LIST OF OUTPUT FLANGES REFER TO:- ‘OUTPUT FLANGE VARIATIONS’
PAGE 61 © Copyright Hewland Engineering Limited 2001-2009
Fig.33
# REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
OUTPUT FLANGES AVAILABLE
LJS-218
LD-218-LH x2
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 HC9-205-1 BEARING HC9-205-1 BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 HC9-206-1 SHIM HC9-206-1 SHIM
22 LD-205-2 SPACER LD-205-2 SPACER
69 LD-205-4 OILSEAL LD-205-4 OILSEAL
91 ORI-203 O-RING ORI-189 O-RING
162 LD-206-2 AND HC9-205-2B
LH BEARING SPACERS LD-206-2 AND HC9-205-2B
LH BEARING SPACERS
163 LD-205-3 BALL BEARING LD-205-3 BALL BEARING
164 CS-1706-B BEARING CARRIER CS-1706-B BEARING CARRIER
166 ORI-006 O-RING ORI-006 O-RING
169 FT-219-1A CIRCLIP FT-219-1A CIRCLIP
190 CS-1706-A BEARING CARRIER CS-1706-A BEARING CARRIER
LD-212-CP CAM & PAWL DIFFERENTIAL
PAGE 62 © Copyright Hewland Engineering Limited 2001-2008
FLANGED FREE DIFFERENTIAL ASSEMBLY SUITABLE FOR INBOARD BRAKE DISCS
Fig.34
PAGE 63 © Copyright Hewland Engineering Limited 2001-2009
Fig.35
LJS-212-F FREE DIFFERENTIAL FOR INBOARD BRAKE DISCS
OUTPUT FLANGES AVAILABLE
CS-1721
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 HC9-205-1 BEARING HC9-205-1 BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 HC9-206-1 SHIM HC9-206-1 SHIM
91 ORI-203 O-RING ORI-189 O-RING
166 ORI-006 O-RING ORI-006 O-RING
169 FT-219-1A CIRCLIP FT-219-1A CIRCLIP
183 HC9-205-3 BALL BEARING HC9-205-3 BALL BEARING
184 CS-1628 BEARING CARRIER CS-1628 SBEARING CARRIER
185 HC9-205-4 OILSEAL HC9-205-4 OILSEAL
188 CS-1731 LH BEARING SPACER CS-1731 LH BEARING SPACER
189 CS-1628-B SPACER CS-1628-B SPACER
# REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
part numbers
PAGE 64 © Copyright Hewland Engineering Limited 2001-2008
FLANGED LIMITED SLIP DIFFERENTIAL ASSEMBLY SUITABLE FOR INBOARD BRAKE DISCS
Fig.36
PAGE 65 © Copyright Hewland Engineering Limited 2001-2009
Fig.37
LD-212 LIMITED SLIP DIFFERENTIAL FOR INBOARD BRAKE DISCS
OUTPUT FLANGES AVAILABLE
CS-1721
CASING
FTR JFR
Position SIDEPLATE ARRANGEMENT SIDEPLATE ARRANGEMENT
# Part No Description Part No Description
7 HC9-205-1 BEARING HC9-205-1 BEARING
20 FTR-205 SIDEPLATE JFR-205 SIDEPLATE
21 HC9-206-1 SHIM HC9-206-1 SHIM
91 ORI-203 O-RING ORI-189 O-RING
166 ORI-006 O-RING ORI-006 O-RING
169 FT-219-1A CIRCLIP FT-219-1A CIRCLIP
181 FTR-205-4 LH BEARING SPACER FTR-205-4 LH BEARING SPACER
182 FTR-205-3 SPACER FTR-205-3 SPACER
183 HC9-205-3 BALL BEARING HC9-205-3 BALL BEARING
184 CS-1628 BEARING CARRIER CS-1628 SBEARING CARRIER
185 HC9-205-4 OILSEAL HC9-205-4 OILSEAL
187 SPA-073 SPACER SPA-073 SPACER
# REFER TO PAGES 25-27,37-39(6sp) OR 45-47(5sp) for other
part numbers
PAGE 66 © Copyright Hewland Engineering Limited 2001-2008
RAMP ORIENTATION
Fig.38
PAGE 67 © Copyright Hewland Engineering Limited 2001-2009
FTR GAITOR ASSEMBLY
Fig.39
GKN GI-69 AND GI2600 TRIPOD JOINTS (NOT SUPPLIED)
PAGE 68 © Copyright Hewland Engineering Limited 2001-2008
FTRE AND FTRL LIGHTWEIGHT TRIPOD ASSEMBLIES (FTRE-218-LAS, FTRE-218 RAS, FTRL-218-LAS, FTRL-218-RAS)
Fig.40
PAGE 69 © Copyright Hewland Engineering Limited 2001-2009
GEARBOX TOOLING
Fig.41
PAGE 70 © Copyright Hewland Engineering Limited 2001-2008
TOOLING PARTS LIST
PAGE 71 © Copyright Hewland Engineering Limited 2001-2009
LOW FRICTION PINION HEAD BEARING TOOLING
Fig.42
PAGE 72 © Copyright Hewland Engineering Limited 2001-2008
INSTALLATION DRAWINGS: MAINCASE AND
BEARING CARRIER
PAGE 73 © Copyright Hewland Engineering Limited 2001-2009 Fig.43
FTR MAINCASE (FTR-201)
PAGE 74 © Copyright Hewland Engineering Limited 2001-2008 Fig.44
JFR MAINCASE (JFR-201)
PAGE 75 © Copyright Hewland Engineering Limited 2001-2009
Fig.45
PAGE 76 © Copyright Hewland Engineering Limited 2001-2008
Fig.46a
OUTPUT FLANGE VARIATIONS
PAGE 77 © Copyright Hewland Engineering Limited 2001-2009
Fig.46b
OUTPUT FLANGE VARIATIONS
PAGE 78 © Copyright Hewland Engineering Limited 2001-2008 Fig.46c
OUTPUT FLANGE VARIATIONS
PAGE 79 © Copyright Hewland Engineering Limited 2001-2009
FTRE-218-LAS AND FTRE-218-RAS
FTRL-218-LAS AND FTRL-218-RAS
Fig.46d
PAGE 80 © Copyright Hewland Engineering Limited 2001-2008
Position Part Number Qty Description
1 BEA-452 1 ROD END
2 HC-202-10 1 PLAIN NUT
3* HYD-071 2 JIC -3 FITTING
3* HYD-072 2 JIC -4 FITTING
4 LD-202-9 2 WASHER
5 NUT-001 1 KAYNUT
6 NUT-004 1 KAYNUT
7 PNU-039 1 ACTUATOR
8 SCR-298 1 HEX HEAD SCREW
9 SCR-358 1 SOCKET HEAD SHOULDER BOLT
10 SGT-244-13 2 SOCKET CAP SCREW
11 SK-2286 1 BRACKET
12 SK-2444-A 1 WASHER
13 WSH-015 1 WASHER
14 WSH-090 1 DOWTY WASHER
Pneumatic Shift Actuator Installation:
A 2 way pneumatic actuator is available for the FTR gearbox, which can be used in conjunction with pneumatic shift systems (such as Hewlands own proven paddle shift system). The actuator bracket mounts directly onto the boss shown on the FTR maincase allowing the actuator to be mounted here and attached to the existing bell crank.
PAGE 81 © Copyright Hewland Engineering Limited 2001-2009
2nd JUNE 2005
Fig.47
PAGE 82 © Copyright Hewland Engineering Limited 2001-2008
Technical Bulletins
FTC DIFFERENTIAL - LOCKING PERCENTAGE RATING.
Below is a formula for rating different ramp angles in terms of percentage of the achievable lock.
The above formula gives a good approximation of the locking force as a percentage of a diff that has been set up with a full complement of working plate surfaces, and a set of 30 degree ramps. It can be seen from the above formula that 34 percent of the locking action is not provided by the ramps. This locking component is due to the reaction forces of the side bevel gears. Put another way, the locking torque can be approximated using this formula :
Where µ is the friction coefficient between the plates. µ=0.1 can be used for steel plates.
LockPercentage=urfacesOfWorkingSPossibleNo
durfacesUseNoOfPlateS*]+
)mpTangent(Ra[
Max34
38
∠
stweenWheelsferableBeTorqueTran=
durfacesUseNoOfPlateS*)]mpTangent(Ra[TorqueCrownwheel *}/415.378{.* µ∠+
PAGE 83 © Copyright Hewland Engineering Limited 2001-2009
16/05/2002
FTR Technical Bulletin No. 01A
AMENDMENT TO BULLETIN No. 01
Bearing Carrier (FTR-202)
This bulletin replaces FTR Technical Bulletin No. 1. Note that the retaining washer has been reduced in diameter to 23mm. This is to ensure that the washer cannot interfere with spacer LD5-229-4. The new WSH-051 will be available from Hewland Engineering. Existing WSH-051 must not be fitted unless they have been modified in diameter to 23mm. It has come to our attention that there is a possibility of the bearing outer track (BEA-002) moving out of position during use. To overcome this problem Hewland Engineering will be adding a 5mm tapped and countersunk hole to the bearing carrier for a bearing retaining screw & washer to be fitted. All our existing and future stock will feature this tapped hole. Its is recommended that all FTR-202 Bearing Carriers are modified as shown below and fitted with an M5 x 10mm long Countersunk screw & washer (Hewland Parts: SCR-023 & WSH-051). The tapped hole will break out of the casting and therefore hydraulic sealant must be used when fitting the screw. This will not be the case on future castings which will be modified for this reason.
PAGE 84 © Copyright Hewland Engineering Limited 2001-2008
James Batchelor Design Engineer
Fig.48
PAGE 85 © Copyright Hewland Engineering Limited 2001-2009
22 February 2002
FTR Technical Bulletin No. 02
Bearing Anti-rotation (FTR-201 & FTR-202)
It has come to our attention that there is a possibility of the bear-ing/outer tracks (BEA-002 & BEA-159) rotating during use. To overcome this problem Hewland Engineering will be adding 2.5mm DIA. x 3.5mm deep dowel holes to the bearing bore faces on the Maincase and Bearing carrier castings, to allow an anti-rotation dowel to be fitted. All our existing and future stock will feature these dowel holes. Its is recommended that all FTR-201 Maincases and FTR-202 Bearing Carriers are modified (as shown below) so that a 2.5mm DIA. X 5mm long dowel (Hewland Part: DOW-018) can be fitted. . FTR-202 Bearing Carrier
Fig.49
PAGE 86 © Copyright Hewland Engineering Limited 2001-2008
FTR-201 Maincase James Batchelor (Design Engineer)
The bearings (BEA-159 & BEA-002) will also require modifica-tion if the anti-rotation dowels are to be fitted. The outer tracks of the bearings will need a 3mm wide x 2mm deep slot ma-chined on the seating face (as shown below).
Fig.50
PAGE 87 © Copyright Hewland Engineering Limited 2001-2009
14/02/03
FTR Technical Bulletin No. 003 Re-pinning of selector barrel (FTR-260)
On a few occasions during the 2002 season, the pins within the selector barrel failed. The specification of the pin was immediately increased and as an act of good faith, for the past year, all barrels returned to the factory have been re-pinned FOC. While this service will continue to be available it will, with effect from this bulletin, cease be FOC. A charge of £50.00 will be made for each barrel returned to Hewland Engineering for re-pinning. Alternatively replace-ment pins (part # DOW-033) are available through your normal Hewland supplier.
PAGE 88 © Copyright Hewland Engineering Limited 2001-2008
27th May 2003
FTR Technical Bulletin No. 004
Barrel pin (DOW-033) To date there are some 300 FTR type gearboxes in service. Of the initial batch of some 20 gearboxes a quantity of the selector barrels were fitted with sub standard pins (see tech bul-letin # FTR 03). This fault was quickly recognised and dealt with. Since that time there have been few instances of pin fail-ure. However, during the course of remanufacture, for our stock, we have taken the precaution of strengthening the pin. The new stronger pins will supersede the earlier version for all new supply, and are recognisable from the earlier version by an identification dimple in one end. . It is not our recommendation that all original pins be changed, but should you so wish, the new pins are available under the same part number through your normal Hewland supplier. As all existing stocks have expired, with effect from this bulletin, all DOW-033 obtained from Hewland Engineering will be to the new specification.
Old specification pin New specification pin
PAGE 89 © Copyright Hewland Engineering Limited 2001-2009
PAGE 90 © Copyright Hewland Engineering Limited 2001-2008
PAGE 91 © Copyright Hewland Engineering Limited 2001-2009
19th July 2004
PAGE 92 © Copyright Hewland Engineering Limited 2001-2008
25th January 2005
Fig.51
PAGE 93 © Copyright Hewland Engineering Limited 2001-2009
3rd February 2005
FTR Technical Bulletin No. 09 FTRL Gears
As you may know, a range of lightweight FTR gearbox parts is in production at Hewland Engineering. We have also carried out a review of the FTR gear ratio situation, with particular respect to the Formula Three market. It has been decided that Hewland will imminently commence production of a range of lightweight FTR gear ratios known as `FTRL` which are aimed at offering the fullest practical weight saving for the Formula Three market. These gears will not be `the ultimate` lightweight components that Hewland could produce, but they will afford a 0.9kg weight saving over a standard FTR layshaft and full gear set, whilst still maintaining long life. Perhaps more relevant is that the weight saving over a prolific non-Hewland full gear set that we have studied will be 0.63kg. In fact certain of these `pirate` gears are actually heavier than our standard FTR, despite narrower tooth face width! The FTRL gears will have narrower face widths than the pirate gears, so the competitive advantage is enhanced due to lower inertia, as `highest diameter` mass is less. The superior tooth form and superior heat treatment found in genuine Hewland FTR gears will still be present in our new lightweight range. This will afford both advantageous weight and superior transmission efficiency over other suppliers. The FTRL gear cluster will come with a new layshaft, for weight reasons. However all splines and fits are the same, which will allow the mixing and matching of FTR and FTRL gears if need be. This should be very cost effective as a way of phas-ing out FTR gears, perhaps during testing. The main message is this: We advise that you do not stock up on inferior competitors gear ratios before the FTRL range is available, as this will cause you competitive disadvantage. Lighter and more efficient gears are coming soon! William Hewland Managing Director
PAGE 94 © Copyright Hewland Engineering Limited 2001-2008
4th February 2005
FTR Technical Bulletin No. 10 FTR Lightened Clutchshafts
As you may know, a range of lightweight FTR gearbox parts is in production at Hewland Engineering. We have also de-cided to offer lightened clutchshafts – specifically for the Formula Three market.
We are now able to offer the following lightened clutchshafts:-
* 2005 spec
Our research shows that some FTR clutchshafts could be re-designed to save in excess of 0.5Kg – any customers who are interested in purchasing lightened clutchshafts for other FTR applications should contact a member of the Hewland En-gineering sales team ([email protected]) to discuss their specific requirements.
James Batchelor Design Engineer
Hewland Part No. Engine/Chassis Approx. Weight Saving (Kg)
FTR-239-35 Mercedes/Dallara* 0.385
FTR-239-36 Mugen/Dallara* 0.37
FTR-239-37 Nissan/Dallara* 0.36
FTR-239-38 Opel/Dallara* 0.39
FTR-239-39 Toyota/Dallara* 0.365
PAGE 95 © Copyright Hewland Engineering Limited 2001-2009
22nd February 2005
FTR Technical Bulletin No. 011 FTR/FTRL 12:34 Pinionshaft – Locking Nut & Ring
Hewland Engineering has recently been made aware of some thread failures on FTR pinionshafts. The occurrence of these failures was limited to the 12:34 ratio (used mainly in Formula 3 applications). Two steps have been taken by Hewland Engineering to ensure future failures are avoided, these are:-
1. All FTR pinionshafts will now feature rolled threads. 2. The ‘problematic’ pinionshaft (12:34) will now feature a longer thread.
Fig. 1 Longer thread on 12:34 pinionshafts (left)
Customers who run 12:34 FTR pinionshafts need to be aware that the new ‘lengthened thread’ parts (which will be phased in over the next few months) require a dif-ferent locking nut and locking ring. The new lock nut (to replace FTR-230) is FTR-230-A and the locking ring is FTR-230-B (which will replace HP-M-4026). For final drive ratios other than 12:34 the nut & ring remain unchanged. These new parts will be available from Hewland stores shortly.
The lightweight FTRL pinionshaft is also affected, as a 12:34 ratio will also feature the longer thread and will therefore require the new locking nut & ring as mentioned above.
James Batchelor (Design Engineer)
PAGE 96 © Copyright Hewland Engineering Limited 2001-2008
FTR Technical Bulletin No.013
POSITION OF GEAR INDICATOR POTENTIOMETER
Fig.52
PAGE 97 © Copyright Hewland Engineering Limited 2001-2009
FTR Technical Bulletin No. FTR-014
It has come to our attention that on some EGT gear-boxes the reverse idler screw (SCR-117) has come loose, even though having been loctited on assembly. This is the same screw and reverse idler design used in the FTR. It is to be noted that no incidents of this screw coming loose on the FTR has been reported to Hewland. To avoid the possibility of it coming loose we have modified the screw to include four holes to facili-tate the use of lockwire and have also modified the maincase FTR-201 as well with a hole to pass it through. We recommend that this modification be done to all gearboxes that you have. Below are the details of the modifications.
SCR-117
FTR-201 MAINCASE
Fig.53
PAGE 98 © Copyright Hewland Engineering Limited 2001-2008
FTR Technical Bulletin No. FTR-015
Pinion Bearing Nut Revision Some customers have reported instances of the pinion bearing nut FGA-222-1A coming loose, during gearbox operation. In an effort to alleviate the loosening of the locknut, the design has been enhanced, increasing its radial thickness, length, and the material specification. This modification has also enabled us to incorporate the washer HC8-222-2A into the locknut, so making the washer redundant. The latest design of locknut has been re-numbered as NUT-031, and the relevant tightening torque has been increased to 150 lbs.ft (205 Nm). As on the earlier locknut, the outside face is grooved, so leaving a thin section which must be peened over in two positions, into the corresponding grooves machined into the bearings threaded diameter. The locknut must also be fitted using loctite 2701 thread lock. If for any reason the locknut is fully fitted (i.e. peened over), and subsequently removed, we would recommend that a new locknut be fitted. N.B. These changes do not apply to Formula BMW applications.
PAGE 99 © Copyright Hewland Engineering Limited 2001-2009
General Technical Bulletin No. GEN-040
HCC AND FTC SIDE AND PLANET GEARS Hewland Engineering has produced various designations of FTC and HCC planet and side bevel gears. For clarity the latest specification gears are: HCC-213-5AF and FTC-213-5AF These gears should not be run with any other designation gears
Fig.54
PAGE 100 © Copyright Hewland Engineering Limited 2001-2008
GENERAL K-NUT TIGHTENING TORQUES
(Nm) (lbs.ins) (lbs.ft)
M5 8.4 75 6.2
M6 12.7 112 9.3
M8 27.0 239 19.9
M10 x 1.50 40.0 354 29.5
M10 x 1.25 50.0 443 36.9
(Nm) (lbs.ins) (lbs.ft)
1/4 13.0 115 9.6
5/16 26.0 230 19.2
3/8 43.5 385 32.1
7/16 64.9 575 47.9
RECOMMENDED TIGHTENING TORQUES FOR METRIC
COARSE SERIES K-NUTS
FITTING TO EN16T STUDS
RECOMMENDED TIGHTENING TORQUES FOR UNIFIED
COARSE SERIES K-NUTS
THREAD
THREADFITTING TO EN16T STUDS
PAGE 101 © Copyright Hewland Engineering Limited 2001-2009
Manual Modification History
Date Modification 04/03/09 Detail view added to page 21, modification history page added 23/03/09 Part numbers colour change page 29, omitted washer added page 23 11/05/09 FTR-212-ADJ graph removed tooling added removed from page 56 24/06/09 Installation Drawing updated to include slave cylinder note 10/09/09 Corrections to output flange details for LJS-218 13/10/09 LJS Specific tooling added to pages 64 and 65, LD Powerflow diff ancillaries corrected 14/10/09 Gaitor Assembly added to page 65 16/10/09 Lightweight flanges added Manual anomalies sorted 03/12/09 General technical bulletin 040 added 11/12/09 Cam and Pawl diff added, Installation drawing updated, Low friction bearings added 19/01/10 Output flanges clarified for LJS differentials 27/01/10 Installation for flanges updated for clarity 23/02/10 Obsolete added to FTRE pages 25/02/10 Low friction bearing tooling page added 16/03/10 Gear order added to page 14 and parts lists drawings 22/03/10 Parts added to parts list on adjustable diff page 26/03/10 Installation drawings corrected 27/04/10 Page 46, item 52 part number corrected. 26/07/10 page 60 parts list corrected, page 58 title changed 16/08/10 Page 49 FTRS parts list updated 24/08/10 Pages 69 & 70 Diff post spacer HP-N-4064 added, spacers page 61 corrected 25/08/10 Differential BOM corrected on FTR-212 and FTR-212-ADJ 23/11/10 Part Number requirement for LD flanges on page 78 corrected 26/01/11 Page 80 - pneumatic actuator information added 02/09/11 Page 46 Item 87 corrected 16/09/11 Pages 24, 29 & 44—Pneumatic shift note added with blanking plug picture. Page 26—Item 78 added. Pages 27, 30—Item 195 removed, Item 233 added. Page 47—Item 233 added. Pages 21 & 41—Note added regarding JFR part number reference 03/11/11 Page 26—Note added regarding items 71 and 87. Page 46— Item 71— description added (FT-230) Page 24—Note edited to reference p29. 24/11/11 Page 60—Output flange changed from LH x2 to RH x2
PAGE 102 © Copyright Hewland Engineering Limited 2001-2008
Manual Modification History
04/01/2012 Page 10 - Alternate Differential bearing preload paragraph added, recommended diff bearing preload figure added (0.013"/0.015")
08/02/2012 Page 46 - Item 53 Changed from FTR– RATIO-HUB to JFR-RATIO-HUB 16/05/2012 Page 26 - Item 89 ORI-203 moved to become part of Item 91 16/07/2012 Page 42 - ‘6th’ Removed from note 26/07/2012 Page 53 - FTR-213-5FD now FTR-213-5A and FTR-213-6FD now FTR-213-6A 24/09/2012 Pages 9 & 70 - Extra tool information added 04/10/2012 Page 15 - Tool reference replaced with page reference Page 67 - Extra tripod joint option added Page 69 - SK-846 A/B/C added Page 70 - Tooling list updated 10/10/12 Page 60 - Output flange list replaced with reference note